Mig C141/ C151 Mag C171/ C201/ C251

Transcription

1 GB Origo Mig C141/ C151 Mag C171/ C201/ C251 Instruction manual GB Valid for serial no. 736-xxx-xxxx

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3 1 SAFETY INTRODUCTION Equipment TECHNICAL DATA INSTALLATION Location Assembly of components Mig C Mig C Mag C171/C201/C Electrical installation Mains power supply Recommended fuse sizes and minimum cable areas OPERATION Connection and control devices Welding without gas Wire feed pressure Replacing and inserting wire Overheating protection MAINTENANCE Inspection and cleaning FAULT TRACING ORDERING OF SPARE PARTS DIAGRAM ORDER NUMBER WEAR PARTS ACCESSORIES Rights reserved to alter specifications without notice. TOCe - 3 -

4 GB 1 SAFETY Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well-acquainted with the operation of the equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment. 1. Anyone who uses the equipment must be familiar with: its operation location of emergency stops its function relevant safety precautions welding and cutting 2. The operator must ensure that: no unauthorised person is stationed within the working area of the equipment when it is started up. no-one is unprotected when the arc is struck 3. The workplace must: be suitable for the purpose be free from drafts 4. Personal safety equipment Always wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves. Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. 5. General precautions Make sure the return cable is connected securely. Work on high voltage equipment may only be carried out by a qualified electrician. Appropriate fire extinquishing equipment must be clearly marked and close at hand. Lubrication and maintenance must not be carried out on the equipment during operation. CAUTION Read and understand the instruction manual before installing or operating. ba47e - 4 -

5 GB WARNING Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill Install and earth the unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. Insulate yourself from earth and the workpiece. Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health Keep your head out of the fumes. Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area. ARC RAYS - Can injure eyes and burn skin. Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. Protect bystanders with suitable screens or curtains. FIRE HAZARD Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE - Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection. Warn bystanders of the risk. MALFUNCTION - Call for expert assistance in the event of malfunction. Read and understand the instruction manual before installing or operating. PROTECT YOURSELF AND OTHERS! WARNING Do not use the power source for thawing frozen pipes. CAUTION This product is solely intended for arc welding. Dispose of electronic equipment at the recycling facility! In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility. As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations. For further information contact the nearest ESAB dealer. ESAB can provide you with all necessary welding protection and accessories. ba47e - 5 -

6 GB 2 INTRODUCTION Mig C141, Mig C151, Mag C171, Mag C201 and Mag C251 are step controlled power sources of a compact design, intended for welding with solid steel, stainless steel or aluminium wire as well as tubular wire with or without shielding gas.it is possible to weld with homogeneous wire/shielding gas and weld with gasless tubular wire by switching the + and - connections on the switching terminal by the wire feed unit. ESAB's accessories for the product can be found on page Equipment The power source is supplied with: Welding gun Return cable with return clamp Shelf for gas cylinder (C151-C251) Instruction manual 3 TECHNICAL DATA Mig C141 Mig C151 Mag C171 Voltage V, 1 50/60Hz V, 1 50/60Hz V, 1 50/60Hz Permissible load at 100% duty cycle 42A/16.1V 67A/17.4V 76A/17.8V 60 % duty cycle 54A/16.7V 87A/18.3V 98A/18.9V 50 % duty cycle - 95A/18.7V - 25 % duty cycle 83A/18.2V - 155A/21.7V 20 % duty cycle 100A/17.0V 150A/16.0V 170A/21.0V Setting range (DC) 35A/15.7V-83A/18.2V (130A/13.4) 30A/15.5V-95A/18.7V (150A/16.0V) 30A/15.5V-155A/21.7 V (170A/21.0) Open circuit voltage V V V Open circuit power 75W 110W 270W Power factor at max load Control voltage V, 50/60Hz V, 50/60Hz 42V, 50/60Hz Wire feed speed m/min m/min m/min Burnback time s Spot welding s Welding gun connection fixed fixed EURO Wire dimension range Max diameter/weight of wire bobbin (Fe) 1.0(Al) 0.8(cored) 0.8(CuSi) (Fe) 1.0(Al) 0.8(cored) 0.8(CuSi) (Fe) 1.0(Al) 0.8(cored) (CuSi) 200mm/5kg 200mm/5kg 300mm/15kg Dimensions lxwxh 650x300x x300x x420x730 Weight 25kg 37,5kg 59kg ba47e - 6 -

7 GB Mig C141 Mig C151 Mag C171 Operating temperature o C o C o C Enclosure class IP 23 IP 23 IP 23 Application classification Mag C201 Mag C251 Voltage V, 1 50/60Hz V, 1 50/60Hz Permissible load at 100% duty cycle 90A/18.5V 110A/19.5V 60 % duty cycle 115A19.7V 140A/21.0V 30 % duty cycle - 200A/24.0V 23 % duty cycle 185A/23.3V - 20 % duty cycle 200A/23.0V 250A/21.0V Setting range (DC) 30A/15.5V-185A/23.3V (200A/23.0V) Open circuit voltage V V Open circuit power 120W 200W Power factor at max load A/16.0V-200A/24.0V (250A/21.0V) Control voltage 42V, 50/60Hz 42V, 50/60Hz Wire feed speed m/min m/min Burnback time s s Spot welding s s Welding gun connection EURO EURO Wire dimension range Max diameter/weight of wire bobbin (Fe) 1.0(Al) (cored) (CuSi) 300mm/15kg (Fe) (Al) (cored) (CuSi) 300mm/15kg Dimensions lxwxh 860x420x x420x730 Weight 68kg 94kg Operating temperature o C o C Enclosure class IP 23 IP 23 Application classification Duty cycle The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid for 40 C. Enclosure class The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid objects or water. Equipment marked IP23 is designed for indoor and outdoor use. ba47e - 7 -

8 GB Application class The symbol indicates that the power source is designed for use in areas with increased electrical hazard. 4 INSTALLATION The installation must be carried out by a professional. Note! Connect the power source to the electricity mains with a network impedance of (C ; C151 - N/A; C171 - N/A; C ; C ) ohm or lower. If the network impedance is higher, there is a risk of flicker in the illuminators. CAUTION This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions. 4.1 Location Position the welding power source in such a way that its cooling air inlets and outlets are not obstructed. 4.2 Assembly of components WARNING! For packing and shipment of the machine the wheels are detached from the unit. Before use attach the wheels according to instruction. ba47e - 8 -

9 GB Mig C141 ba47e - 9 -

10 GB Mig C ba47e

11 GB Mag C171/C201/C Electrical installation ba47e

12 GB 4.4 Mains power supply Check that the unit is connected to the correct mains power supply voltage, and that it is protected by the correct fuse size. A protective earth connection must be made, in accordance with regulations. Rating plate with supply connection data 4.5 Recommended fuse sizes and minimum cable areas Voltage V Mig C141 Mig C151 Mag C171 Mag C201 Mag C V, 1 50/60Hz V, 1 50/60Hz V, 1 50/60Hz V, 1 50/60Hz Current A at 100% duty cycle at 60% duty cycle V, 1 50/60Hz at % duty cycle 11.5 at 25% 13.0 at 50% 27.8 at 25% 36.2 at 23% 38.7 at 30% at 20% duty cycle Cable area mm 3 x x x x x 4.0 Fuse slow A (16*) NB: The mains cable areas and fuse sizes shown above are in accordance with Swedish regulations. They may not be applicable in other countries: make sure that the cable area and fuse sizes comply with the relevant national regulations. *- In the supply networks of high level of short circuit power (low impedance of network) it is recommended to use 16A fuse. 5 OPERATION General safety regulations for handling the equipment can be found on page 4. Read through before you start using the equipment! WARNING Rotating parts can cause injury, take great care. WARNING To prevent the reel from sliding off the hub: Lock the reel in place by turning the red knob as shown on the warning label attached next to the hub. ba47e

13 GB WARNING Secure the equipment - particularly if the ground is uneven or sloping. 5.1 Connection and control devices 1 Mains supply switch with indicator lamp, only in C171/C201/C251 5a Return cable with clamp, fixed, only in C140/C150/C170/C200 2 Orange indicator lamp, overheating 6 Knob for spot welding - ON/OFF and time setting, only in C171/C201/C251 3 Welding voltage switch C141: OFF + 4 steps (mains ON/OFF) C151: OFF + 7 steps (mains ON/OFF) C171: 8 steps C201: 12 steps C251: 12 steps 7 Knob for wire speed setting 4 EURO - connector for welding gun, only in C171/C201/C251 4a Welding gun, fixed, only in C141/C151 5 Connection for return cable (-),only in C251 8 Digital instrument - V / A, only in C171/C201/C251 (option,see page 26) 9 Knob for burn-back time setting. In C251 located in wire feeder compartment. In C171/C201 located on control board. ba47e

14 GB 5.2 Welding without gas (Fe) (Al) (cored) (CuSi) connected when delivered (cored) 5.3 Wire feed pressure Start by making sure that the wire moves smoothly through the wire guide. Then set the pressure of the wire feeder's pressure rollers. It is important that the pressure is not too great. ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ ÏÏ Fig 1 Fig 2 To check that the feed pressure is set correctly, you can feed out the wire against an insulated object, e.g. a piece of wood. When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed rollers should slip. If you hold the gun approx. 50 mm from the piece of wood, the wire should be fed out and bend (fig. 2). 5.4 Replacing and inserting wire Open the side panel. Disconnect the pressure sensor by folding it backwards, the pressure rollers slide up. Straighten the new wire for cm. File away burrs and sharp edges from the end of the wire before inserting it into the wire feed unit. Make sure that the wire goes properly into the feed roller track and into the outlet nozzle and the wire guide. Secure the pressure sensor. Close the side panel. ba47e

15 GB 5.5 Overheating protection When the machine is switched on with the mains switch, [1] or [3] depending on machine model, indicator lamp [1] is on and lamp [2] off - the machine is ready to operate. If the internal temperature becomes too high, the welding is interrupted and disabled. This state is indicated by lighting of the orange indicator lamp [2] on the front of the machine. It resets automatically when the temperature has fallen. 6 MAINTENANCE Regular maintenance is important for safe, reliable operation. CAUTION All guarantee undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the guarantee period. 6.1 Inspection and cleaning Check regularly that the power source is free from dirt. The power source should be regularly blown clean using dry compressed air at reduced pressure. It should be cleaned more frequently in dirty environments. Otherwise the air inlet/outlet may become blocked and cause overheating. Welding gun The welding gun's wear parts should be cleaned and replaced at regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact tip. The brake hub The hub is adjusted when delivered, if readjustment is required, follow the instructions below. Adjust the brake hub so that wire is slightly slack when wire feed stops. Adjusting the braking torque: Turn the red handle to the locked position. Insert a screwdriver into the springs in the hub. Turn the springs clockwise to reduce the braking torque Turn the springs counter-clockwise to increase the braking torque. NB: Turn both springs the same amount. ba47e

16 GB 7 FAULT TRACING Try these recommended checks and inspections before sending for an authorised service technican. Type of fault Actions No arc Check that the mains power supply switch is turned on. Check that the welding current supply and return cables are correctly connected. Check that correct current value is set. Welding current is interrupted during welding Check whether the thermal overload trip has operated (indicated by the orange lamp on the front). Check the main power supply fuses. Thermal overload trips Check to see whether the air inlets/outlets are clogged. operate frequently Make sure that you are not exceeding the rated data for the power source (i.e. that the unit is not being overloaded). Poor welding performance Check that the welding current supply and return cables are correctly connected. Check that the correct current value is set. Check that the correct welding wires are being used. Check the main power supply fuses. Check the wire feed unit - if proper rolls are applied and properly set the pressure of the wire feeder's pressure rollers 8 ORDERING OF SPARE PARTS Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. Mig C141/ C151 Mag C171/ C201/ C251 is designed and tested in accordance with the international and European standards IEC-/ EN , IEC-/ EN It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard. Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication. ba47e

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23 Mig C141/ C151 Mag C171/ C201/ C251 Order number Ordering no. Denomination Notes Origo TM Mig C V 1~50/60Hz Origo TM Mig C Origo TM Mig C Origo TM Mig C Origo TM Mig C251 Technical documentation is available on the Internet at ba47o ESAB AB 2012

24 Mig C141/ C151 Mag C171/ C201/ C251 Wear parts (W. F. Mechanism ) Item Denomination Ordering no. Notes A Feed roller Ø mm Fe, cored wire, CuSi Ø 1.0mm Al B Liner Fe, cored wire, CuSi Al C Contact tip Ø 0.6mm Fe Ø 0.8mm Fe, cored wire, CuSi Ø 1.0mm Al The rollers are marked with wire dimension in mm, some are also marked with inch. Welding with aluminium wires. In order to weld with aluminium wires, proper rollers, nozzles and liners for aluminium wires MUST be used. It is recommended to use 3m long welding gun for aluminium wires, equipped with appropriate wear parts. ba47w ESAB AB 2012

25 Mig C141/ C151 Mag C171/ C201/ C251 (W. F. Mechanism / ) Item Denomination Ordering no. Notes A Pressure roller B Feed roller Ø mm Fe, Ss, cored wire. Ø mm Fe, Ss, cored wire. Ø mm Fe, Ss, cored wire. Ø mm Al wire. C Inlet nozzle D Insert tube Plastic, must be used together with item , for welding with Al wire. Steel, must be used together with item E Outlet nozzle Must be used together with item , for welding with Al wire. Must be used together with item The rollers are marked with wire dimension in mm, some are also marked with inch. Welding with aluminium wires. In order to weld with aluminium wires, proper rollers, nozzles and liners for aluminium wires MUST be used. It is recommended to use 3m long welding gun for aluminium wires, equipped with appropriate wear parts. ba47w ESAB AB 2012

26 Mig C141/ C151 Mag C171/ C201/ C251 Accessories Digital meter Transformer kit for CO 2 heater, 42V Traction kit for C ba47a ESAB AB 2012

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32 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: Fax: BELGIUM S.A. ESAB N.V. Brussels Tel: Fax: BULGARIA ESAB Kft Representative Office Sofia Tel/Fax: THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: Fax: DENMARK Aktieselskabet ESAB Herlev Tel: Fax: FINLAND ESAB Oy Helsinki Tel: Fax: FRANCE ESAB France S.A. Cergy Pontoise Tel: Fax: GERMANY ESAB GmbH Solingen Tel: Fax: GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: Fax: ESAB Automation Ltd Andover Tel: Fax: HUNGARY ESAB Kft Budapest Tel: Fax: ITALY ESAB Saldatura S.p.A. Bareggio (Mi) Tel: Fax: THE NETHERLANDS ESAB Nederland B.V. Amersfoort Tel: Fax: NORWAY AS ESAB Larvik Tel: Fax: POLAND ESAB Sp.zo.o. Katowice Tel: Fax: PORTUGAL ESAB Lda Lisbon Tel: Fax: ROMANIA ESAB Romania Trading SRL Bucharest Tel: Fax: RUSSIA LLC ESAB Moscow Tel: +7 (495) Fax: +7 (495) SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: Fax: SPAIN ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: Fax: SWEDEN ESAB Sverige AB Gothenburg Tel: Fax: ESAB international AB Gothenburg Tel: Fax: SWITZERLAND ESAB AG Dietikon Tel: Fax: UKRAINE ESAB Ukraine LLC Kiev Tel: +38 (044) Fax: +38 (044) North and South America ARGENTINA CONARCO Buenos Aires Tel: Fax: BRAZIL ESAB S.A. Contagem-MG Tel: Fax: CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: Fax: MEXICO ESAB Mexico S.A. Monterrey Tel: Fax: USA ESAB Welding & Cutting Products Florence, SC Tel: Fax: Asia/Pacific AUSTRALIA ESAB South Pacific Archerfield BC QLD 4108 Tel: Fax: CHINA Shanghai ESAB A/P Shanghai Tel: Fax: INDIA ESAB India Ltd Calcutta Tel: Fax: INDONESIA P.T. ESABindo Pratama Jakarta Tel: Fax: JAPAN ESAB Japan Tokyo Tel: Fax: MALAYSIA ESAB (Malaysia) Snd Bhd USJ Tel: Fax: SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: Fax: SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: Fax: UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: Fax: Africa EGYPT ESAB Egypt Dokki-Cairo Tel: Fax: SOUTH AFRICA ESAB Africa Welding & Cutting Ltd Durbanvill Cape Town Tel: +27 (0) Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page ESAB AB